updating pre 96 klr-650 for safety

[William Whalen]

Appreciate any advise, I have a 92 KLR-650 that I love and have no intention of getting rid of it, but I am interested in updating it. Could you please inform me of the parts and where I can buy them to update my KLR and make it safer. I am taking about engine modification such as counter balancers, springs, ect to improve performance and safety. Thanks, Bill Whalen Central Florida 92 KLR-650

>From: DSN_klr650@egroups.com >Reply-To: DSN_klr650@egroups.com >To: DSN_klr650@egroups.com >Subject: [DSN_klr650] Digest Number 496 >Date: 1 Sep 2000 02:31:13 -0000 > >Visit the KLR650 archives at >http://www.listquest.com/lq/search.html?ln=klr650 >Support Dual Sport News... dsneditor@... >Let's keep this list SPAM free! > >Visit our site at http://www.egroups.com/group/DSN_klr650 >To unsubscribe from this group, send an email to: >DSN_klr650-unsubscribe@egroups.com > >------------------------------------------------------------------------ > >There are 25 messages in this issue. > >Topics in this digest: > > 1. Re: super do-it-yourself touring tool carrier > From: Tom Simpson > 2. Age NKLR > From: "Stuart Mumford" > 3. Re: NKLR - Call for assistance > From: Toby Lampson > 4. Age > From: "Roy James" > 5. kick start > From: "Roy James" > 6. Cowl-support > From: Renn > 7. RE: Crap - got ticketed > From: JIM JAMES > 8. RE: dickhead > From: JIM JAMES > 9. RE: Moron Crap-Ticketed NKLR > From: JIM JAMES > 10. RE: super do-it-yourself touring tool carrier > From: JIM JAMES > 11. Re: Skid Plate affects KLR Shifting / Or, I'm an idiot > From: "John Magee" > 12. Re: Slime ??? > From: TLrydr@... > 13. Elden Carl > From: "Jim & Shannon Morehead" > 14. ELDEN CARL SUMMER SPECTACULAR...ON THE AIR > From: "Robert Morgan" > 15. Elden Carl's balancer shaft adjustment procedure > From: "Robert Morgan" > 16. IT'S ALMOST TIME!!!! > From: Toby Lampson > 17. Elden > From: "Jim & Shannon Morehead" > 18. Re: Elden > From: "Robert Morgan" > 19. Re: Elden Carl's balancer shaft adjustment procedure > From: Mark > 20. Elden > From: "Jim & Shannon Morehead" > 21. Difference in engines.. > From: "Kurt Simpson" > 22. Re: Elden Carl's balancer shaft adjustment procedure > From: Krgrife@... > 23. Next greatest 'weak link' > From: Toby Lampson > 24. Re: Elden > From: "Robert Morgan" > 25. Re: Difference in engines.. > From: "Kurt Simpson" > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 1 > Date: Thu, 31 Aug 2000 19:53:50 -0400 > From: Tom Simpson >Subject: Re: super do-it-yourself touring tool carrier > > > >Harry Thames wrote: > > > > If you don't need the large tool holder, you can get a welding rod >storage container from Lowes or Home Depot for around $7. Its > > about 3 inches in diameter and 18 inches long with a water tight cap. >Gives you a little more room for those deep compression > > bumps. > > > There are also British-made containers available on the military >surplus market that hold 81mm mortar shells. These are very similar to >the welding rod containers but are a bit larger, a bit heavier and a bit >cheaper. Guess what I keep in one of mine? Welding rod! > > Personally, I took a .50 caliber ammo can and cut it down to about 2 >inches high and bolted it down to the front frame tube. Looks and works >great. > >-Tom >'96 KLR 650 > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 2 > Date: Thu, 31 Aug 2000 17:00:11 -0700 > From: "Stuart Mumford" >Subject: Age NKLR > >Quoth the elder Mr. Mumford; >"There are old riders, and there are bold riders, but there aren't many old >bold riders." > >CA Stu > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 3 > Date: Thu, 31 Aug 2000 17:11:08 -0700 > From: Toby Lampson >Subject: Re: NKLR - Call for assistance > >You asked for it you got it........ >Becoming a Dirt Rider before a Street Rider is 'Priceless'. > >You gain automatic crash avoidance reflexes while first learning in the >dirt, >that you will be able to gain......no other way. > >If you master dirt first, when you go to street you'll be better than >75% of those out there......and you'll have the automatic responses >that will save your life. > >I'm such a believer in the Dirt First rule I think one should >be required to have one of these three before being allowed >to carry a MC permit. >1)- 1,500 hours supervised offroad exp.......or 'confidence' on >blue diamonds. > >2)- Two offroad wrecks where 'blood' was drawn. > >3) Two black diamond solo rides. > > >Living begins where the pavement ends........as they say. > >If you want to test my philosophy do this: >First get a friend with a pickup. >You get in the back. >A) Tell him to accelerate to 25mph, maintain speed, you jump out the >back-----on asphalt. >B) Do everything the same, but now jump out >-------------------------------on dirt. > > >a believer in the Divine.............Slide > > > >Rev.Chuck wrote: > > > The other crowd that seems to be dying off are brand new riders between >their mid 40s and mid 50s... > > > > Ok, I have had enough of this - > > My brother in law is starting out on a FZR600, I have tried to tell him >about the benifits of a DS, but Noooo. > > > > So, I told him a friend may drop him a line or two... > > > > I guess I am asking the KORG to SPAM him...? > > > > No, just each of you drop him a line or two to *educate* him away from >the 200MPH hamburger maker and mount a real mud slinging dust blower. > > > > MCLARK00@... > > > > (he knows that it is coming... :^) > > > > == > > Rev. Chuck > > :^)>+ > > A13 > > http://klr650.50megs.com > > ~~~~~~~~~~~~~~~~~~~~~~~~ > > > > _____________________________________________________________ > > Email Powered by Everyone.net > > > > Visit the KLR650 archives at > > http://www.listquest.com/lq/search.html?ln=klr650 > > Support Dual Sport News... dsneditor@... > > Let's keep this list SPAM free! > > > > Visit our site at http://www.egroups.com/group/DSN_klr650 > > To unsubscribe from this group, send an email to: > > DSN_klr650-unsubscribe@egroups.com > > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 4 > Date: Fri, 01 Sep 2000 00:21:10 -0000 > From: "Roy James" >Subject: Age > >About age I'm 37 have been riding off and on for close to 20 years.My >first bike when I was about 20 was a Harley Sportster. I nearly got >killed on it.While not fast by Ninja standards it was way to much for >someone of limited experience(and handled like crap).I just bought a >2001 klr650. I nearly let my ego push me into buying a ricerocket.I'm >glad I didn't the klr is plenty powerful enough for any normal use >and it can do many things a regular street bike simply can't. It's >the best thing since individually wrapped vacuum packed sliced cheese. > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 5 > Date: Fri, 01 Sep 2000 00:24:31 -0000 > From: "Roy James" >Subject: kick start > > the Illustrated parts breakdown(y2klr) shows parts for a kick start. >Does anyone know about installing it? The local Kawasaki dealer told >a fried of mine it couldn't be fitted. Any comment? > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 6 > Date: Thu, 31 Aug 2000 20:24:45 -0400 (EDT) > From: Renn >Subject: Cowl-support > >Thank's to all for the cowl-support straightening advice, it sounds like >the >way to go is to lash the bike to an immobile object and the cowl-support to >an anchored come-along. A bit of finesse and a bit of brut force, I like >it! :-* Later. > >Renn >A15 ( Rocinante ) > > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 7 > Date: Thu, 31 Aug 2000 20:31:34 -0400 > From: JIM JAMES >Subject: RE: Crap - got ticketed > >I reckon every group has one. This is where the weird turn pro..... > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 8 > Date: Thu, 31 Aug 2000 20:35:00 -0400 > From: JIM JAMES >Subject: RE: dickhead > > > >---------- >From: Tom Myers[SMTP:TomMyers@...] >Sent: Wednesday, August 30, 2000 3:19 PM >To: DSN_klr650@egroups.com >Subject: [DSN_klr650] dickhead > > > >What, exactly, is a dickhead? >You'll know 'em from their posts. james > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 9 > Date: Thu, 31 Aug 2000 20:52:13 -0400 > From: JIM JAMES >Subject: RE: Moron Crap-Ticketed NKLR > >I think he said he was unsubbing. Now, I may wrong, but isn't this the way >the PTL club got started? Until he wrote the post to Jim I thought maybe >it was a member of the Karolina Kawasaki Klub. James > >---------- > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 10 > Date: Thu, 31 Aug 2000 21:18:11 -0400 > From: JIM JAMES >Subject: RE: super do-it-yourself touring tool carrier > >dEAR sIR...cAN YOu sTiLL cARRy yOre wELDInG rOdS iN iT? mY tooL iS tO bIG 4 >iT. JAMES IN S.C. > >If you don't need the large tool holder, you can get a welding rod >storage container from Lowes or Home Depot > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 11 > Date: Fri, 01 Sep 2000 01:18:41 -0000 > From: "John Magee" >Subject: Re: Skid Plate affects KLR Shifting / Or, I'm an idiot > > > Eric > > Colorado Springs > > A13L "Beef" > > ps-my Moose touches the engine case on the left side, have heard >this could > > cause probs, looks to me like a stronger arrangement. Opinions? > > > >I had the same problem with mine. I thought more than anything it >might create an annoying noise with the plate against the vibrating >engine. I loosened all the straps and the front clamp, wedged the >bash plate over and tightened everything up again. It left a gap >about 3/16 inch. It's been there through a few weeks of tough stuff >and seems to have stayed in place. > >John >Canuk on a KLR > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 12 > Date: Thu, 31 Aug 2000 22:01:03 EDT > From: TLrydr@... >Subject: Re: Slime ??? > > To the all knowing BORG > I have 2 bottles of slime in front of me. One says for tube tires$7.95 >and >is thick, And the other says tubless tires $3.95 and is or looks to be >thinner....... >Whats the deal?????????????????????????????? > > Mike > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 13 > Date: Thu, 31 Aug 2000 21:01:20 -0500 > From: "Jim & Shannon Morehead" >Subject: Elden Carl > >Hi guys, > >I'm here at the appointed time and station. Anyone else out there? > >Jim > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 14 > Date: Thu, 31 Aug 2000 18:57:16 -0700 > From: "Robert Morgan" >Subject: ELDEN CARL SUMMER SPECTACULAR...ON THE AIR > > Ladies and gentleman, Elden is in the house. I thought we would start >this evening with a posting of Elden's recently written instructions for >balancer shaft adjustment. This has been submitted for publication to DSN >so this is a scoop, I hope Kurt and Ron will forgive us but Elden feels >this >is a very timely topic. > So any questions? > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 15 > Date: Thu, 31 Aug 2000 18:57:45 -0700 > From: "Robert Morgan" >Subject: Elden Carl's balancer shaft adjustment procedure > >BALANCER ADJUSTMENT PROCEDURE FOR POST 1996 KAWASAKI KLR-650s: >By ELDEN CARL > > > > Even though Kawasaki has greatly improved the balancer adjustment >mechanism in KLR 650s they're still faulty if not adjusted properly. The >main problem is that there is no snap ring retaining the balancer >adjustment >lever. The lever can actually stick to the adjustment bolt when it is >turned out, and get cocked and bent when the bolt is turned back in. When >the engine is started, it, (the lever) can be hit by the back of the large >starter gear nearby. > I have experimented with the balancer mechanism adjustment on the >engine I am building and come up with what I think is the only sure fire >procedure. > A. Lean the bike to the right as far as you can. (I lean mine against >the >wall, in gear, while the engine is still hot so the oil won t be too >sticky). > B. Lower the bashplate and remove the plug from the adjuster bolt. > C. Loosen the bolt less than turn and then turn it back in until it >just >starts to tighten. > D. Back the bolt out again to exactly turn and tap the end of it >gently >with a plastic mallet. > E. Turn the bolt back in and torque it to 8.5ft. lbs. > F. Replace the rubber plug and bash plate and go riding. > > What about pre-1996 KLRs ? For liability reasons I will give you no >advice as to adjustment procedures or torque specifications. If the old >bolt has ever been over torqued the lever may never move again. If the >brittle old spring is broken the chain may loosen instead of tighten when >adjusted and then jump off track, destroying your engine. > ` I would not ride a KLR in heavy traffic that did not have the new >parts and my drive washer installed or at least the pins and springs that >drive the balancer inspected to make sure they are all there and in good >condition. > If you think I m being overly dramatic ask Kurt Grife, Jim Bellach, >Dan >Turner, or Rupert Humphrey: all of whom have had their engines blown up by >the balancer gremlins. Rupert lost two, one at open throttle. PLEASE FIX >YOUR PRE-1996 KLR 650. > I have been accused of helping to drive down the price of used >pre-1996 >KLR650s, but a properly updated KLR650 is as good as a new one and better >in >some ways (more on that later). > I am counting on Kurt Grife a bunch to document the bulletproofing of >his KLR and to help me force Kawasaki to prove they aren t the same guys >who >enslaved our servicemen during WW2 by fixing these potentially deadly KLR >balancer mechanisms and clutch baskets which are throwing chunks of spring >out into the oil stream. > > > > > > > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 16 > Date: Thu, 31 Aug 2000 18:56:39 -0700 > From: Toby Lampson >Subject: IT'S ALMOST TIME!!!! > >For Morg, the Borg.......and the DSN Elden Carl Show........ > >and Dawn's halftime dancer's????????? > >I wanna see Dawn's legs! >Show me your legs Dawn! Slide > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 17 > Date: Thu, 31 Aug 2000 21:06:12 -0500 > From: "Jim & Shannon Morehead" >Subject: Elden > >Hi Elden, > >I've seen your name in print many times during the last several months, but >I'm sorry to say I don't know much about you. Are you a pro mechanic? > >Jim > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 18 > Date: Thu, 31 Aug 2000 19:05:15 -0700 > From: "Robert Morgan" >Subject: Re: Elden > >I have never worked as a professional mechanic. However, I have been >building motorcycles and engines since 1955 and built long travel offroad >bikes long before the "big four". >(Morgan's note.....Elden is far too fussy at what he does to make money at >it!) >----- Original Message ----- >From: Jim & Shannon Morehead >To: DSN_klr650 DSN_klr650@egroups.com> >Sent: Thursday, August 31, 2000 7:06 PM >Subject: [DSN_klr650] Elden > > > > Hi Elden, > > > > I've seen your name in print many times during the last several months, >but > > I'm sorry to say I don't know much about you. Are you a pro mechanic? > > > > Jim > > > > > > Visit the KLR650 archives at > > http://www.listquest.com/lq/search.html?ln=klr650 > > Support Dual Sport News... dsneditor@... > > Let's keep this list SPAM free! > > > > Visit our site at http://www.egroups.com/group/DSN_klr650 > > To unsubscribe from this group, send an email to: > > DSN_klr650-unsubscribe@egroups.com > > > > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 19 > Date: Thu, 31 Aug 2000 22:16:50 -0400 > From: Mark >Subject: Re: Elden Carl's balancer shaft adjustment procedure > >At 6:57 PM -0700 8/31/00, Robert Morgan wrote: > >BALANCER ADJUSTMENT PROCEDURE FOR POST 1996 KAWASAKI KLR-650s: > >By ELDEN CARL >SNIP > > I have been accused of helping to drive down the price of used >pre-1996 > >KLR650s > >Works for me! Keep at it so I can expand my fleet. >Mark >B2 >A2 > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 20 > Date: Thu, 31 Aug 2000 21:16:48 -0500 > From: "Jim & Shannon Morehead" >Subject: Elden > >I really don't have any intelligent quesitons to pose tonight. I just >mounted a new rear tire on my A13 today and my old bod is a little stiff >and >sore from the experience. I really had to work at getting the last little >bit of the bead to seat. > >Should I take it a little easy on the new tire for a few days? Do you guys >worry about tire balance much? > >Jim > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 21 > Date: Fri, 01 Sep 2000 02:19:10 -0000 > From: "Kurt Simpson" >Subject: Difference in engines.. > >Hi Elden, > >Well, I haven't forgotten that you promised a rundown on the subtle >differences between the KLR engines over the years...ready to go? > >Kurt > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 22 > Date: Thu, 31 Aug 2000 22:21:58 EDT > From: Krgrife@... >Subject: Re: Elden Carl's balancer shaft adjustment procedure > >In a message dated 8/31/00 7:05:13 PM Pacific Daylight Time, >robertlmorgan@... writes: > >of > his KLR >> > >More photos for this were taken today and my moto-journalist riding buddy >will be doing a magazine article (probably two) on this subject and on my >rebuild that is being completed under Elden's guidance. >Kurt G. > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 23 > Date: Thu, 31 Aug 2000 19:14:29 -0700 > From: Toby Lampson >Subject: Next greatest 'weak link' > >Hello Elden- > Kudos and Tacos for the generosity of your time >venerable sir............. > Question: Other than the two upgrades(balancer/clutch >basket) for pre 96' bikes...... > And the one 'gear piece' that replaces 8 moving parts..... > > What is the next weakest link you see yourself addressing in >the KLR in the future.....................our cam tensioner perhaps? > > >Slide > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 24 > Date: Thu, 31 Aug 2000 19:17:15 -0700 > From: "Robert Morgan" >Subject: Re: Elden > >If you are careful as you are prying on the tire bead to be careful to push >the bead down into the drop center of the rim (where the spokes are) you >will find it to be a piece of cake. I carefully balance every tire, knobby >or otherwise. Your bike will run smoother and your suspension will be able >to keep the tire on the ground. >Elden >----- Original Message ----- >From: Jim & Shannon Morehead >To: DSN_klr650 DSN_klr650@egroups.com> >Sent: Thursday, August 31, 2000 7:16 PM >Subject: [DSN_klr650] Elden > > > > I really don't have any intelligent quesitons to pose tonight. I just > > mounted a new rear tire on my A13 today and my old bod is a little stiff >and > > sore from the experience. I really had to work at getting the last >little > > bit of the bead to seat. > > > > Should I take it a little easy on the new tire for a few days? Do you >guys > > worry about tire balance much? > > > > Jim > > > > > > Visit the KLR650 archives at > > http://www.listquest.com/lq/search.html?ln=klr650 > > Support Dual Sport News... dsneditor@... > > Let's keep this list SPAM free! > > > > Visit our site at http://www.egroups.com/group/DSN_klr650 > > To unsubscribe from this group, send an email to: > > DSN_klr650-unsubscribe@egroups.com > > > > > > > >________________________________________________________________________ >________________________________________________________________________ > >Message: 25 > Date: Thu, 31 Aug 2000 20:27:44 -0600 > From: "Kurt Simpson" >Subject: Re: Difference in engines.. > >Morgan, what say we give the chat room a try? > >Kurt > > > >________________________________________________________________________ >________________________________________________________________________ > > >

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[Chris Krok]

OK, the wind tunnel report on motorcycle fairings is finally up. You can view it at http://www.galcit.caltech.edu/~stingray/awt/mcreport.html You'll notice a sudden change in image size and format at photo page 4, because I had done the scanning in two separate sessions, and somehow forgot how I was doing it the first time! I still haven't actually read much of the report myself, but it sounds like a good way to waste a Friday morning. If anyone has any questions about the methodologies, please post to the list, and I'll try to answer as best as I can. Or at least make up something that sounds good. Apologies for taking so long to post this, esp. to Rev. Chuck, who was very interested. However, I now have a 700-hp fan installed in my wind tunnel that wasn't there Wednesday. Speaking of bad mechanics, we've been using the same rigging company for all of the wind tunnel installation, and they're generally great guys. However, one came yesterday who had never been here before, and kept going on about how he's been a millwright for 42 years. This immedately turned into a battle between the "crusty old expert" and the "thinks-he-knows-it-all-young-engineer." Now, I respect the fact that this guy has been a millwright for 42 years, and he did make a couple of good points. However, I've been working on this tunnel and this tunnel alone for over 2 years now. First, we have to wait for this guy to mark a centerline on the concrete fan pad. I try to explain to him that we're not centering the fan on the pad, we have to align it with the two mating parts of the tunnel. No, we have to have a centerline. Did we ever look at it after that? No. I won't get into the rest of the arguments, but the final straw was with the leveling bolts. To level the fan, there are four 1-1/2" nuts welded along either side, to accept 1-1/2" bolts. Unfortunately, three of them weren't properly centered over their holes, and the bolts bound up as they tried to cut threads in the plate underneath. First of all, I had to listen to this guy bitch that we didn't have a 1" drive ratchet. (We had a breaker bar.) I was using a big-mother cresent wrench on my side. Then, one of the bolts starts binding up on his side. Now, when we first lowered the fan, we set it on wood blocks so we could run the bolts through easily. There was paint on the nut threads, but it still didn't take much to run the good bolts in. However, when this guy feels the bolt bind up, what does he do? Instead of stopping to think about what's happening, he puts a cheater bar on the socket, and gets another person to help him run it in! They got about an inch through, and couldn't go any farther. Now, I'm going to have to spend all morning getting this thing out so I can make a reducing bushing and run it in there. Man, I was almost doing time in San Quentin for assault with a deadly spud wrench! So much for 42 years of experience. One other thing... Last night, I was inspecting my dickhead. Much to my chagrin, I found that it's only a single-valve model. Does anyone know of a 4-valve aftermarket replacement? Will I need a stronger cam chain with that? Thanks! Chris -- Dr. J. Christopher Krok Project Engineer, Adaptive Wall Wind Tunnel Graduate Aeronautical Laboratories, California Institute of Technology MS 205-45 Phone: 626.395.4794 Pasadena, CA 91125 Fax: 626.449.2677